Form for Casting Light Weight Composite Concrete Panels

ABSTRACT

A concrete form for supporting a steel frame above a pouring pad comprises a vertical wall configured to be fastened to the steel frame, a marker on the vertical wall for spacing the frame a predetermined distance above the pouring pad, and a sealing member extending from a lower edge of the wall for sealing the form to the pouring pad. Preferably, the vertical wall has an upper portion, a horizontally offset lower portion, and a shoulder there between which engages an edge of the steel frame. The sealing member is preferably a lip extending from the vertical wall at an obtuse angle and engaging the pouring pad at an obtuse angle.

CROSS-REFERENCE

This application claims priority from co-pending U.S. provisional patent application Ser. No. 60/693,823 filed Jun. 24, 2005. This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/565,317 which is a National Stage of PCT/US2004/023155 filed Jul. 21, 2004 which claims priority from U.S. provisional patent application Ser. No. 60/488,821 filed Jul. 21, 2003.

FIELD OF THE INVENTION

The present application is directed to forms for forming concrete, and in particular forms for casting light weight composite concrete panels.

BACKGROUND OF THE INVENTION

Composite concrete and steel frame panels have been used to construct buildings, and in particular as exterior cladding panels in industrial, commercial and residential structures. It is well known to assemble composite building panels at one location and to transport the panels to a construction site for use in fabricating structures. The use of prefabricated building components substantially reduces the labor costs at both the manufacturing and assembly processes.

Composite concrete panels, such as those disclosed in PCT Application Serial No. PCT/US2004/023155 to Smith, which is incorporated herein by reference, are made of metal frames partially imbedded in concrete for providing exterior wall systems. In many cases, the panels are supported on the building structure, and are not intended to bear any loading other than wind loading, however composite panels can also be used in load bearing applications. Generally, the panel includes a concrete slab having a finished exterior surface. Structural steel studs, such as C-shaped channels, are assembled into a frame and the frame is partially embedded into the concrete slab. Preferably the slab is light weight concrete, such a foam concrete, as disclosed in the above referenced Smith PCT application. Mechanical systems, insulation and wall board or other interior finish are installed on the interior of the panel.

Traditionally, composite concrete panels are formed by assembling an outer form comprised of wood or metal rails on a pouring pad. Interior forms can be placed with the outer from to block-out apertures for doors and windows. The outer and optional inner forms define a volume into which concrete is poured. Typically a steel frame, and reinforcing rods or mesh are embedded in the concrete. The steel can be assembled and placed within the form before the concrete is poured, or can be lowered and pressed into the concrete shortly after the concrete is poured. It is generally necessary to seal the outer and interior form members to the pouring pad. This is conventionally done with plastic sheeting or by caulking between the forms and the pouring pad to prevent the seepage of concrete underneath the forms. After at least partial curing of the concrete panel, the form members are stripped and removed.

The installation, sealing and removal of the forms to the pouring pad are laborious and time-consuming. Additionally, the workspace requires extensive clean-up after each panel is successively cast.

Accordingly, there is a need for an improved form for casting composite concrete panels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section through a first embodiment of a concrete form of the invention secured to a frame and retaining concrete slurry.

FIG. 2 is a cross-section through two adjacent composite concrete panels formed with the first embodiment form.

FIG. 3 is a partially cut away perspective view of a second embodiment of a concrete form of the invention.

FIG. 4 is a partially cut away perspective view of a third embodiment of a concrete form of the invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a first embodiment of a concrete form 10 is shown attached to a steel frame 12 with fastener 14. A layer of reinforcing material 16, such as a slit and expanded steel mat, is secured to the frame. The reinforcing material and a portion of the steel frame member are partially embedded in light-weight concrete 18, as disclosed in PCT Application Serial No. PCT/US2004/023155. The form 10 functions to retain concrete slurry 18, space the steel frame 12 a predetermined distance D above pouring pad 20, and seal the form to the pouring pad.

The form 10 comprises a vertical wall 22 having an upper portion 24 and a lower portion 26. The upper vertical wall portion is configured to be fastened to the frame member 12 with fastener 14. A shoulder 28 is formed between the upper and lower wall portions. The lower vertical wall portion is horizontally offset from said upper wall portion. A sealing member, namely, lip 30 extends at an obtuse angle from said lower vertical wall and is configured to form an obtuse angle with the pouring pad. The lip is preferably flexible and resilient, but with sufficient strength to support the frame.

The shoulder 28 functions as a marker to locate the frame at a predetermined distance D above pouring pad 20. This distance D can vary as determined by the architect or engineer. Typically, distance D is about one inch.

The lip 30 functions as a lip seal to seal the form to the pouring pad. Because the flexible lip is set at an obtuse angle, as shown in FIG. 1, the weight of the concrete slurry 18 will force the lip downwardly into sealing engagement with pouring pad 20.

The composite concrete panel is preferable manufactured by first assembling the steel frame, and placing the frame upside down on the pouring pad. Reinforcing steel is then secured to the top of the upside down frame. Form members 10 are then fastened to the outer perimeter of the steel frame and such interior apertures as may be desired. Because the frame is upside down, the forms are secured upside down, that is with the lip 30 extending in an upward and inward direction. The shoulder 26 is nested with the edge of the frame, facilitating quick and easy assembly with no need to measure distances. The form members are secured to the frame with fasteners 14, such as screws. After the forms are in place, the assembly is flipped over, so that lips 30 engage the pouring pad 20. Then the concrete can be poured into the interior of the form. The concrete is preferably a light weight concrete, such a foam concrete. Because the concrete is light weight the plastic forms 10 have sufficient strength to retain the concrete without need for timber or steel rails or other substantial structural elements. When the concrete has at least partially cured, the forms may be optionally stripped and removed by removing the fasteners. It is desirable however to leave the forms in place during storage and transport to protect the edges of the composite concrete panels.

FIG. 2 shows two concrete panels 32 a and 32 b fabricated using forms 10. Adjacent panels 32 a and 32 b are joined together with a plurality of fasteners, e.g. screw 34, extending between frame members 12 a and 12 b. The lip 30 of form 10 functions to form chamfers 36 a and 36 b on the edge of each concrete panel. The horizontal offset between the lower 26 and upper 24 wall portions creates a desirable reveal 38 between panels 32 a and 32 b. The reveal is preferably filled with a sealing material 40, such as caulk or grout.

FIG. 3 illustrates a second embodiment 110 of the concrete form of the invention. The features of the second embodiment that correspond to like features of the first embodiment have the same reference numerals, but in the 100 series. Form 110 comprises an “L” shaped member for supporting a frame member 112 of a composite concrete panel above a pouring pad 120. The form member 110 is attached to the frame member 112 with fasteners 114. During assembly of the panel, the form members 110 are preferably disposed on the perimeter of a frame assembly 18 to permit the flow of concrete slurry (not shown) to partially embed the frame assembly in a concrete slab.

The form member 110 comprises a vertical wall 122, and a sealing member comprising a horizontal leg 129 and seal 130. The seal 130 sealingly engages the pouring pad 120. Seal 130 prevents the seepage of concrete slurry under the form member 110 obviating the need to wrap the forms in plastic or the need to caulk the perimeter of the forms. The seal 130 deforms against the pouring pad 120 to retain the concrete slurry within the confines of the form.

The vertical wall 122 has at least one, but preferably plural markers for setting the height of frame 112 above the pouring pad 120. The markers comprise ridges 127 disposed on an inside surface 121 for indexing the relative location of the frame member 112 with the form member 110 and pouring pad 120. Although raised ridges 127 are disposed on the inside surface 121, it is contemplated that other indicators may be used, such as a shoulder, recessed grooves, lines or spaced markers. Preferably, a plurality of ridges are disposed at vertically spaced intervals to facilitate selection of different heights for spacing the frame above the pouring pad and thereby the concrete cover over the frame and reinforcing materials.

Form members 110 are optionally removed from the panel after the concrete is cured. The horizontal leg 129 will cause the perimeter edges of the concrete panel to be slightly recessed with respect to an outer face of the concrete panel. If desired, grout or caulking can be added around the perimeter of the concrete panel to provide a flush finish with the remainder of the concrete panel. One or more ribs 137 are preferably disposed on the interior surface of leg 129 which will form corresponding grooves in the edges of the concrete panel to improve bonding of the grout or caulk to the panel. As indicated above, the form member 110 optionally may be permanently or temporally retained on the concrete panel. It is desirable to retain the form on the panel during storage and transport to protect the panel edges from damage. Referring now to FIG. 4, a third embodiment of the concrete form 210 of the invention is shown. The features of the third embodiment that correspond to like features of the first and second embodiments have the same reference numerals, but in the 200 series. The third embodiment is similar to the second embodiment, except that horizontal leg 229 is directed outwardly rather than inwardly. As in the second embodiment, the frame 212 is mounted to the inside surface 221 of vertical wall 222. Concrete is poured onto the pouring pad 220 to a desired height, preferably embedding a portion of the frame assembly 212. A seal 230 on the bottom surface of leg 229 retains the concrete within the confines of the form. However, unlike the second embodiment, when forms 210 are removed from the concrete panel, the resulting peripheral edges of the panel are flush with the remainder of the outer surface of the panel. In the third embodiment, unlike the second embodiment, it is impractical to leave the form on the panel during storage or transport because of the projecting leg 229.

A single form may be used in either of the orientations shown in the second and third embodiments. Markers may be placed on both sides of the vertical wall 122, 222. Thereby, the form is reversible and can be used in either orientation.

The form members 10, 110, 210 can be inexpensively manufactured of extruded plastic or other material having sufficient strength to hold the frame member above the pouring pad and retain concrete slurry. In the first embodiment, lip seal 30 is preferably integrally formed with vertical wall 22. In the second and third embodiments, seal 130, 230 may be made separately and attached to form member 110, 210. Seal 130, 230 preferably has a greater resiliency, i.e. is softer, than the form member 110, 210.

While specific embodiments of the present concrete form have been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects as defined in the claims. 

1. A concrete form for supporting a steel frame above a pouring pad, said form comprising a vertical wall configured to be fastened to the frame; a marker on said vertical wall for spacing the frame a predetermined distance above the pouring pad; and a sealing member extending from a lower edge of said vertical wall for sealing the form to the pouring pad.
 2. A concrete form as in claim 1, said vertical wall comprising an upper portion and a lower portion, and said marker comprising a shoulder between said upper and lower wall portions.
 3. A concrete form as in claim 2, wherein said upper and lower wall portions are horizontally off-set from one another at said shoulder.
 4. A concrete form as in claim 1, wherein said sealing member comprises a lip extending from said vertical wall at an obtuse angle, and engaging the pouring pad at an obtuse angle.
 5. A concrete form as in claim 1, where in said sealing member comprises a leg extending horizontally from said vertical wall and a seal on said leg configured to engage the pouring pad.
 6. A concrete form as in claim 5, further comprising one or more ribs on an interior surface of said horizontal leg.
 7. A concrete form for supporting a frame member above a pouring pad, said form comprising, a vertical wall having an upper portion and a lower portion, a shoulder between said upper and lower wall portions for supporting the frame member at a predetermined distance above the pouring pad, and a sealing member on said lower wall configured to engage the pouring pad.
 8. A concrete form as in claim 7, wherein said sealing member comprises a lip extending from said lower wall at an obtuse angle.
 9. A concrete form as in claim 7, wherein said lower wall is horizontally off-set from said upper wall to form a reveal in an edge of a concrete panel cast with the form.
 10. A concrete form for supporting a frame member above a pouring pad, said form comprising, an upper vertical wall configured to be fastened to the frame member, a lower vertical wall, said lower wall being horizontally offset from said upper wall, a shoulder between said upper and lower walls configured to engage an edge of the frame member, and a lip extending at an obtuse angle from said lower vertical wall and configured to engage the pouring pad at an obtuse angle, said upper wall, lower wall, shoulder and lip being a unitary extrusion. 